Factory Millwork vs On-Site Carpentry: Cost & Quality Comparison
Comprehensive analysis of factory millwork versus traditional site carpentry—understand cost differences, quality standards, timeline impact, and make the right choice for your luxury interior project.
At a Glance: Factory vs Site Carpentry
Factory Millwork
- CNC precision (±0.5mm tolerance)
- Climate-controlled manufacturing
- Lacquer booth finishes
- 60% faster installation
- Minimal site disruption
Site Carpentry
- Lower upfront cost (15-30% less)
- Real-time design changes possible
- Manual accuracy (±3-5mm tolerance)
- Quality depends on craftsman skill
- Significant dust and noise
Understanding the Two Approaches
What is Factory Millwork?
Factory millwork involves manufacturing cabinetry, wardrobes, and architectural woodwork in a controlled facility using CNC machinery, automated cutting systems, and professional finishing equipment. Components are precision-cut, pre-finished in lacquer booths, and transported to site for assembly.
Fulcro's factory process includes: digital CAD/CAM programming, moisture-tested substrate selection, CNC routing and edge banding, multi-stage sanding, spray booth lacquer application, and quality inspection before delivery. On-site work is limited to assembly, leveling, and hardware installation.
What is Site Carpentry?
Site carpentry (traditional approach) involves skilled carpenters building furniture piece-by-piece at the project location using handheld tools, table saws, and manual joinery techniques. Materials are cut on-site, assembled in place, and finished with brush/roller application or spray guns.
This method relies heavily on individual craftsman expertise and offers flexibility for design modifications during execution. However, quality consistency varies, finishing standards are limited by site conditions, and the process generates significant dust and waste.
Detailed Cost Comparison
Here's a comprehensive cost breakdown for a typical 3 BHK luxury apartment in Bangalore (wardrobe package):
| Cost Factor | Site Carpentry | Factory Millwork |
|---|---|---|
| Master Bedroom Wardrobe (10 ft) | ₹1,20,000 - ₹1,80,000 | ₹1,60,000 - ₹2,40,000 |
| Two Bedroom Wardrobes (8 ft each) | ₹1,60,000 - ₹2,20,000 | ₹2,00,000 - ₹2,80,000 |
| TV Unit & Storage (Living) | ₹60,000 - ₹90,000 | ₹80,000 - ₹1,20,000 |
| Kitchen Cabinets (Modular) | ₹2,00,000 - ₹2,80,000 | ₹2,60,000 - ₹3,60,000 |
| Study Table & Bookshelf | ₹40,000 - ₹60,000 | ₹50,000 - ₹80,000 |
| Total Package Cost | ₹5,80,000 - ₹8,10,000 | ₹7,50,000 - ₹10,60,000 |
| Cost Difference | Factory millwork costs 25-30% more but includes superior finishes and faster execution | |
Important Note: Cost gaps narrow significantly for premium finishes. High-gloss lacquer or veneer work that costs ₹2,000/sq ft on-site can be achieved for ₹1,400-1,600/sq ft in factory due to automation and controlled finishing environments.
Quality Comparison: What You Get
Dimensional Accuracy & Tolerances
Factory Millwork
±0.5mm
CNC precision ensures perfect alignment, consistent gaps, and seamless joinery. Doors close flush, drawers slide smoothly, and panels meet precisely.
Site Carpentry
±3-5mm
Manual measurement and cutting lead to visible gaps, misalignment, and inconsistent reveals. Quality depends heavily on craftsman skill.
Finish Quality & Durability
| Finish Aspect | Site Carpentry | Factory Millwork |
|---|---|---|
| Surface Smoothness | Manual sanding, visible imperfections | Machine-sanded 180-220 grit, mirror-smooth |
| Paint/Lacquer Application | Brush/roller marks, uneven coating | Spray booth, consistent 40-60 micron coating |
| Edge Finish | Manual edge banding, visible joints | Machine edge banding, seamless integration |
| Moisture Resistance | No controlled testing, variable performance | BWR/BWP ply tested, guaranteed moisture resistance |
| Warranty Period | 6 months - 1 year (informal) | 2-5 years (documented warranty) |
Timeline & Installation Impact
Factory Millwork Timeline
- Design finalization:1-2 weeks
- Factory manufacturing:3-4 weeks
- On-site installation:1-2 weeks
- Total Duration:5-8 weeks
Site Impact: Minimal dust, low noise, faster occupancy, parallel work possible
Site Carpentry Timeline
- Design finalization:1 week
- Material procurement:1-2 weeks
- On-site fabrication:4-6 weeks
- Total Duration:6-9 weeks
Site Impact: Heavy dust, continuous noise, delays in other trades, cleaning required
When to Choose Each Approach
Choose Factory Millwork When:
- Project requires European-level finishes or lacquer work
- Tight tolerances and precision joinery are critical (luxury villas, high-end apartments)
- Occupied home renovation where dust and disruption must be minimized
- Timeline pressure requiring parallel manufacturing and faster installation
- Design is finalized and changes during execution are unlikely
Choose Site Carpentry When:
- Budget constraints require lowest upfront investment (mid-range projects)
- Design flexibility during execution is essential (evolving client preferences)
- Site conditions require real-time adjustments (old buildings, uneven walls)
- Simple painted or laminate finishes are acceptable (not high-gloss or lacquer)
- Access to a skilled, experienced carpenter with proven track record
Fulcro's Hybrid Approach
Fulcro combines the best of both worlds: factory precision with site-level craftsmanship. Our process:
- 1CNC-cut components manufactured in climate-controlled facilities with moisture-tested substrates and lacquer booth finishes
- 2Master craftsman installation ensuring perfect fit, addressing site irregularities, and maintaining factory quality standards
- 3On-site finishing touches for custom details, hardware integration, and final quality checks before handover
This hybrid model delivers factory-grade quality with the flexibility to handle site-specific challenges—the optimal solution for luxury residential interiors in Bangalore.
Ready for Factory-Grade Millwork?
Discuss your project with Fulcro's millwork experts. We'll help you choose the right approach based on your budget, timeline, and quality expectations.
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